Panel connector and panel assembly using same

ABSTRACT

A panel connector has a central elongated structural member and two pairs of flanges projecting generally outward from the central elongated structural member and toward one another. The flanges hold corresponding flanges from panels. The panel connector may also have two spines attached thereto with the flanges attached to the spines. The central elongated structural member mats have differing configurations.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a panel connector and a panel assembly using the panel connector and, more specifically, to a panel connector that connects two panels together with flanges extending therefrom to create a structural panel assembly.

2. Technical Background

The use of panels in construction for roofs and walls for houses, sheds, rooms, and other buildings is known. The panels, which are usually only on one side of the wall are typically joined together with cleats., clips, or fasteners. A second set of panels are needed for the second side of wall, particularly if the wall is to be load-bearing wall or an outside wall. The clips used to hold the panels together typically do not have sufficient strength to be the only structural members joining the panels in the wall. This complicates and makes the building process slower and more expensive than it needs to be. A panel connector is needed that allows panels to be easily and structurally secured to one another to allow for rapid and secure construction of walls for buildings.

SUMMARY OF THE INVENTION

Disclosed herein is a panel connector that allows for panels to be interconnected in a safe, sound, and structural manner as well as a panel assembly using the panel connectors.

In one aspects a panel connector is disclosed that includes a central elongated structural member having an outer surface and a length, a first pair of flanges extending away from a first portion of the outer surface of the central elongated structural member, each of the flanges in the first pair of flanges projecting generally outwardly from the central elongated structural member and projecting inwardly toward one another at a predetermined angle relative to the central elongated member, and a second pair of flanges extending away from a second portion of the outer surface of the central elongated structural member, each of the flanges in the second pair of flanges projecting generally outwardly from the central elongated structural member and protecting inwardly toward one another at a predetermined angle relative to the central elongated member

In some embodiments the central elongated structural member is annular in cross section.

In one embodiment the predetermined angle is about 400.

In other embodiments, the central elongated structural member has an opening extending therealong to receive electrical and optical cabling.

In another aspect, a panel assembly, is disclosed that includes at least two panels, each of the at least two panels having a first outer covering and a second outer covering spaced from one another, each of the first and second outer coverings having flanges along opposing sides and projecting inward toward each other and backward toward the panel and at least one panel connector, the at least one panel connector comprising a central elongated structural member and two pair of flanges extending outwardly from the central elongated structural member, each flange in each of the pair of flanges engaging one flange from each of two of the at least two panels to secure the at least two panels to one another.

Additional features and advantages of the invention will be set forth in the detailed description which follows and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention, and are intended to provide an overview, or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows in cross section a prior art cleat attached to two pieces of sheet metal.

FIG. 2 shows in cross section another prior art cleat attached to two pieces of sheet metal;

FIG. 3 is a cross sectional view of one embodiment of a panel connector according to the present invention engaging one side of two panels;

FIG. 4 is exploded view of a part of a panel assembly according to the present invention showing one embodiment of a panel connector and a portion of two panels that are to be joined by the panel connector;

FIG. 5 is a cross sectional view of another embodiment of a panel connector according to the present invention engaging one side of each of the two panels, and

FIGS. 6-12 illustrate alternative embodiments of panel connectors according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

A prior art cleat 1.0 is illustrated in FIG. 1. The cleat 10 has a central flat portion 12 with two end portions 14,16 that are folded back over the central flat portion 12. Thus, the end portions make an angle of 0° relative to the flat portion. The area 18 between the ends portions 14,16 and the central flat portion 12 is slightly larger than the thickness of the pieces of sheet metal 20 that the cleat 10 connects. As can be seen in FIG. 1, each of the edges 22 of the pieces of sheet metal 20 are similarly folded back over the sheet metal, allowing the edges 22 to be captured and held in the area 18 of the cleat 10. Cleat 10 only captures one edge of each of the pieces of sheet metal 20 on a wall, which is insufficient to maintain structural integrity if the pieces of sheet metal were to be used as a wall, especially as a structural or load-bearing wall.

A second prior art cleat 30 is illustrated in FIG. 2. The cleat 30 also has a flat central portion 32 and two flanges 34.36 that are folded and have an interior angle of about 40°. The cleat 30 captures the bended portion 38 of the pieces of sheet metal 40. The bended portion 38 is bent twice, which allows the end of the pended portion 38 to be captured and at least partially secured in the vertices 42 of the cleat 30. However, cleat 30 only captures one edge of the piece of sheet metal 40 on a wall, which is insufficient to maintain structural integrity if the pieces of sheet metal were to be used as a wall, especially %as a structural or load-bearing wall.

One embodiment of a panel connector 100 according to the present invention is illustrated in FIG. 3. The panel connector 100 includes a central elongated structural member 102 having an outer surface 104 and an inner surface 106, which defines an opening 108 that preferably, extends the length of the central elongated structural member 102, making the central elongated structural member 102 an annular member. Panel connector 100 preferably has at least two generally flat surfaces or portions 110 (four are illustrated in FIG. 3) to which an elongated spine 120 is attached. The central elongated structural member 102 is made from steel (preferably 14 to 25 gauge), but any appropriate materials may be used, including for example, aluminum, plastics, and fiber composites. As shown best in FIG. 3, two of the elongated spines 120 are preferably attached to generally flat surface 110 or the central elongated structural member 102. The elongated spine 120 and the central elongated structural member 102 may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.).

The elongated spine 120 preferably has two flanges 122,124 attached thereto, which extend away from the elongated spine 120 and the central elongated structural member 102, but towards one another to approximate a triangle. In one preferred embodiment, the elongated spine 120 and the two flanges 122,124 are a single, integral piece, but they need not be. The two flanges 122,124 preferably, make an internal angle relative to the spine 120 that is less than 70° and more preferably, about 40°.

As best illustrated in FIG. 4, the elongated spine 120 and the two flanges 122,124 are preferably the same length, although it is possible for the elongated spine 120 to be either longer or shorter than the two flanges 122,124 and still fall within the scope of the present invention. The flanges 122,124 preferably extend at least 80% and more preferably 100% of the length of the pamel connector 100. The elongated spine 120 and two flanges 122,124 are also made from steel (14 to 25 gauge), but also be made of any other appropriate material.

The panel connector 100 attaches to one side of each of two panels 130. The panels 130 are typically laminated, having a core 132 and two outside coverings 134,136. On at least two opposing sides of the panels 130, the two outside coverings 134,136 extend beyond the edge of the core 132 and project inward toward the core 132 to create flanges 138. Thus, there will be at least four flanges 138 on each panel 130, two on each of the edges 140. As illustrated in FIG. 3, each of the flanges 138 preferably have two bends that each make a 90° turn with the prior portion of the flanges 138 to make a generally U-shaped flange. The outside coverings 134,136 may be made of any appropriate material, but are preferably made of either steel or aluminum, particularly when the panels 130 are to be used as an outside wall in a building. The flanges 138 from adjacent panels 130 are secured between the flanges 122,124 of the panel connector 100 and create a tight seam 142. The panel connector 100 and the two flanges 122,124 provide sufficient structural strength to the panels 130 to support the bending and traverse structural loads that are imposed on the panel assembly. In other words, no other structural elements or devices are needed to secure the panels 130 to one another (the panel assemblies would obviously need to be secured to a floor or trusses however).

It should be noted that the construction of the panel connector 100 makes the seam 142 relatively tight and generally waterproof. However, in the event that water does make it between two adjacent panels 130 at seam 142, the water would be trapped within the confines of the elongated spine 120 and two flanges 122,124. The water would then run down to the bottom of the panel connector 100, where it can be properly channeled out of the wall.

Another embodiment of a panel connector 200 is illustrated in FIG. 5. The panel connector 200 includes a central elongated structural member 202 having an outer surface 204 and an inner surface 206 that defines an opening 208 that preferably extends the length of the central elongated structural member 202. The central elongated structural member 202 preferably has an opening 218, giving the central elongated structural member 202 generally a C-shaped configuration in cross section. Panel connector 200 preferably has at least two generally flat surfaces or portions 210 to Which the elongated spines 120 are attached. The central elongated structural member 202 is made from steel (14 to 25 gauge), but any appropriate materials may be used, including for example, aluminum, plastics, and fiber composites. As with the prior embodiment, two of the elongated spines 120 are preferably attached to the generally flat surfaces 210 of central elongated structural member 202. The panel connector 200 is attached to the panels 130′, which are the same as panels 130, but have different flanges 138′, As illustrated in FIG. 5, the flanges 138′ also extend inward and toward one another, but are only bent once into a V-shaped configuration. This configuration also allows for increased contact between the flanges 138′ and the panel connector 200.

Alternative embodiments of panel connectors are illustrated in FIGS. 6-12. In FIG. 6, the panel connector 300 is of a unitary construction. The panel connector 300 has a central elongated structural member 302, an outer surface 304, and an inner surface 306 that defines an opening 308 that preferably extends the length of the panel connector 300, making the panel connector 300 annular and generally rectangular, although it may be of any appropriate configuration or shape. For example, it may have a C-shaped configuration as illustrated in FIG. 5, or be more square, I-shaped, or U-shaped as discussed in more detail below. It may also have a round or even an irregular shape as long as it is structurally sound to provide support to the panels. The flanges 322,324 are also integrally formed, rather than being attached as separate elements to a central member. The flanges 322,324 also preferably make an internal angle B with the flat, outer surface 304 that is less than 7(r and more preferably about 40°.

Another embodiment of a panel connector 400 according to the present invention is illustrated in FIG. 7. The panel connector 400 is similar to panel connector 100 except that the elongated spine 420 has a different configuration. In particular, panel connector 400 includes a central elongated structural member 402 having an outer surface 404 and an inner surface 406 that defines an opening 408 that preferably extends the length of the central elongated structural member 402, making the central elongated structural member 402 an annular member. Panel connector 400 preferably has at least two generally flat surfaces 410 to which the elongated spine 420 is attached. As noted above, central elongated structural member 402 and elongated spine 420 may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.).

The elongated spine 420 preferably has two flanges 422,424 attached thereto. Flanges 422,424 have a first portion 422 a,424 a, which extend away from the central elongated structural member 402 (and elongated spine 420) and each other, and a second portion 422 b,424 b, which extend back towards one another. The second portions 422 b,424 b of flanges 122,124 preferably, make an angle relative to the flat surface 410 (and spine 420) that is less than 70° and more preferably about 40°. In one preferred embodiment, the elongated spine 420 and the two flanges 422,424 are a single, integral piece, but they need not be. As in prior embodiments, the elongated spine 420 and the two flanges 422,424 are preferably the same length, although it is possible for the elongated spine 420 to be either longer or shorter than the two flanges 422,424 (and the central elongated structural member 402 as well) and still fall within the scope of the present invention. The elongated spine 420 and two flanges 422,424 are made from steel (preferably 14 to 25 gauge), but also be made of any other appropriate material.

The panel connector 450 is similar to panel connector 400 in that is has flanges 472,474 that each have two portions, but the panel connector 450 is or a unitary construction.

Another the panel connector 500 is illustrated in FIG. 9. The panel connector 500 includes a central elongated structural member 502 having an outer surface 504. The outer surface 504 of panel connector 500 preferably has two generally concave surfaces 506 and two generally flat surfaces 510. The central elongated structural member 502 is preferably made from steel, but any appropriate materials made be used, including for example, aluminum, plastics, and fiber composites.

The panel connector 500 also has the elongated spine 120 attached to each of the two generally flat surfaces 510. As with the prior embodiments, the elongated spine 120 and the central elongated structural member 502 may be welded, molded, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.). The spine 120 is preferably the same as noted above with regard to panel connector 100.

It should also be noted that the central elongated structural member 502, the elongated spine 120, and the two flanges 122,124 may be of a unitary construction, i.e., one piece, as with the panel connector 300 illustrated in FIG. 6 and be within the scope of the present invention.

Another embodiment of a panel connector 550 is illustrated in FIG. 10. The panel connector 550 is similar to the panel connector 500, but the central elongated structural member 552 generally has an I-shaped configuration rather than the concave configuration of panel connector 500. The panel connector 550 also has the elongated spine 120 attached to each of the two generally flat surfaces 560. As with the prior embodiments, the elongated spine 120 and the central elongated structural member 552 may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.). The spine 120 is preferably the same as noted above with regard to panel connector 100. Panel connector 550 may also be of a unitary construction rather than having the various components as illustrated in FIG. 10.

Another embodiment of a panel connector 600 is illustrated in FIG. 11. The panel connector 600 is similar to the unitary panel connector 300 of FIG. 6, but rather than the central elongated structural member 602 having a generally rectangular shape, it has a generally square configuration. The panel connector 600 similarly has integrally formed flanges 322,324.

It may be more appropriate to use the configuration of panel connector 600 with panels that are thinner than those illustrated in FIG. 3 or that have longer flanges, allowing for the more square design of panel connector 600. Panel connector 600 may also be constructed with a separate central elongated structural member and an attached spine with two flanges (e.g. FIG. 3 or FIG. 7).

Another embodiment of a panel connector 650 is illustrated in FIG. 12. The panel connector 650 is similar to the unitary panel connector 200 of FIG. 5, but rather than having a generally rectangular shape, the panel connector 650 has a central elongated structural member 652 that is generally a U-shaped configuration with only three sides. While the panel connector 650 is illustrated with the elongated spines 120 attached to two generally flat surfaces 660 of central elongated structural member 652, the flanges may be integral with the central elongated structural member 652. As with the prior embodiments, the elongated spine 120 and the central elongated structural member 652 may be welded or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.), or they may be a unitary member. The spine 120 is preferably the same as noted above with regard to panel connector 100.

It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. 

1. A panel connector comprising: a central elongated structural member having an outer surface and a length; a first pair of flanges extending away from a first portion of the outer surface of the central elongated structural member, each of the flanges in the first pair of flanges projecting generally outwardly from the central elongated structural member and projecting inwardly toward one another at a predetermined angle relative to the central elongated member; and a second pair of flanges extending away from a second portion of the outer surface of the central elongated structural member, each of the flanges in the second pair of flanges projecting generally outwardly from the central elongated structural member and projecting inwardly toward one another at a predetermined angle relative to the central elongated member.
 2. The panel connector according to claim 1 wherein the predetermined angle is less than 70°.
 3. The panel connector according to claim 1 wherein the predetermined angle is about 40°.
 4. The panel connector according to claim 1, wherein the central elongated structural member is generally annular in cross section.
 5. The panel connector according to claim 1 wherein the central elongated structural member has a cross section that is selected from the group including generally C-shaped, generally U-shaped, generally rectangular, generally square, and generally I-shaped.
 6. The panel connector according to claim 1 wherein the first and second pairs of flanges extend at least 80% of the length of the central elongated structural member.
 7. The panel connector according to claim 1, wherein the central elongated structural member has an opening extending therealong to receive electrical and optical cabling.
 8. The panel connector according to claim 1, wherein the flanges are directly attached to the central elongated structural member.
 9. The panel connector according to claim 1, further comprising an elongated spine attached to each of the first and second portions of the outer surface of the central elongated structural member and each elongated spine having one pair of the flanges attached thereto.
 10. The panel connector according to claim 1 wherein the first and second portions of the external surface of the central elongated structural member are generally flat.
 11. The panel connector according to claim 1 wherein each of the flanges in the first and second pairs have a first portion and a second portion, the First portion adjacent to and extending generally away from the central elongated structural member and the second portion connected to the first portion aid extending generally inward toward the other of the pair of flanges.
 12. The panel connector according to claim 1, wherein the central elongated member together with the first and second pairs of flanges provide structural support to panels in a panel assembly.
 13. A panel assembly comprising: at least two panels, each of the at least two panels having a first outer covering and a second outer covering spaced from one another, each of the first and second outer coverings having flanges along opposing sides and projecting inward toward each other and backward toward the panel; and at least one panel connector, the at least one panel connector comprising a central elongated structural member and two pair of flanges extending outwardly from the central elongated structural member, each flange in each of the pair of flanges engaging one flange from each of two of the at least two panels to secure the at least two panels to one another.
 14. The panel assembly according to claim 13, wherein the panels have a height and the panel connector extends at least 80% of the height of the panels.
 15. The panel assembly according to claim 13, wherein the panel assembly is used as a portion of a structure selected from structures that includes a wall, a roof, a floor, and a fence. 